base sheets - bgc innova™ design | fibre cement...

DURASCAPETM

BASE SHEETS

MAY 2015

AUSTRALIAN OWNED & MANUFACTURED WWW.BGCINNOVADESIGN.COM.AU

INTRODUCING INNOVA™

MAY 2015

BGC’S STUNNING RANGE OF FACADE, LINING AND FLOORING PRODUCTS, INNOVA™ WILL MOVE YOU TO REASSESS YOUR CONCEPT OF EXCELLENCE IN FAÇADES AND FLOORING SYSTEMS. DURABLE AND DYNAMIC, FRESH AND CONTEMPORARY, INNOVA™ IS ALREADY TURNING INDUSTRY HEADS. NOW LET THE INNOVA™ RANGE OF CLADDING AND FLOORING PRODUCTS BREATHE NEW LIFE INTO YOUR CREATIVITY AND PROJECT SPECIFICATION.

DURASCAPE™ IS A 9MM-THICK BASE SHEET. EXCELLENT FOR COVERING LARGE AREAS, ITS 5MM WIDE SHIPLAP JOINT GIVES THE SHEET A SUBTLE VERTICAL SHADOW LINE.

TO CREATE AN APPEALINGLY ‘RENDERED’ LOOK, TRY FINISHING DURASCAPE™ ONSITE WITH A ROLL-ON TEXTURED PAINT.

DURASCAPETM BASE SHEETS:

/ LIGHTWEIGHT AND DURABLE/ IDEAL FOR SINGLE-STOREY AND MEDIUM HEIGHT INSTALLATIONS WHERE YOU WANT LARGE PANELS/ QUICK INSTALLATION – NO NEED FOR TAPED AND FILLED JOINTS/ PANELS UNAFFECTED BY TERMITES, AIR, STEAM, SALT AND SUNLIGHT/ CAN BE FINISHED IN A RANGE OF DECORATIVE COATINGS

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CONTENTS

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APPLICATIONS / 5ADVANTAGES / 5ENERGY EFFICIENCY CONSIDERATIONS / 5PRODUCT INFORMATION / 5FIRE RESISTANCE / 5FINISHING / 5DURABILITY / 5THERMAL CONDUCTIVITY / 5SIZES AND WEIGHT / 5SHEET TOLERANCES / 5HANDLING AND STORAGE / 6COASTAL AREAS / 6ACCESSORIES AVAILABLE FROM BGC / 7FASTENERS / 7CONSTRUCTION DETAILS / 8INSTALLATION DETAILS / 9-19WARRANTY / 19THERMAL BREAKS / 20BUSHFIRE/BOUNDARY WALL / 21

DURASCAPETM

MAY - 2015

APPLICATIONS

ADVANTAGES

Durascape™ is a strong and durable base sheet which has a subtle shiplap vertical joint that is suitable for finishing with a range of decorative coatings.

Durascape™ is suitable for low to medium rise buildings and can be used on both timber and steel framed buildings. It is also ideal for renovations and alterations to existing dwellings.

/ Gives a subtle 5mm vertical shadow line/ Is lightweight and durable/ Quick to install because it eliminates the need for taped and filled joints and vertical set joints/ Panels are not affected by termites, air, steam, salt or sunlight

ENERGY EFFICIENCY CONSIDERATIONS

Energy efficiency requirements have been introduced into the Building Code of Australia (BCA) for both commercial and residential buildings. Thermal heat transfer into and out of the building envelope will affect the running cost of the building and careful consideration of thermal heat transfer needs to be addressed by the architects, engineers and building designers. Thermal bridging through steel framing will diminish the total R-Value; thermal conductance of the wall. Thermal breaks are required for steel framed buildings and should be installed between the steel frame and the Durascape™ panels. Thermal break tapes should have a minimum R-Value of 0.2.

PRODUCT INFORMATION

Durascape™ panels are manufactured from Portland cement, finely ground silica, cellulose fibres and water. Panels are cured in a high-pressure steam autoclave to create a durable, dimensionally stable product.

Durascape™ panels are manufactured to the Australian / New Zealand Standard AS/NZS 2908.2-2000 Cellulose-Cement Products, Part 2: Flat sheets and Durascape™ is classified as Type A-Category 2.

FIRE RESISTANCE

FINISHING

BGC Fibre Cement products have been tested in accordance to Australian Standard AS1530.3.

These tests deemed the following Early Fire Hazard Indices:

/ Ignition Index 0/ Spread of Flame Index 0/ Heat Evolved Index 0/ Smoke Developed Index 0-1

Paint & Coatings Manufacturers such as Dulux, Wattyl, Taubmans, Macs Architectural Coatings and Acryloc manufacture decorative coatings that are recommended for Fibre Cement substrates. Please refer to the manufacturer for details. Always follow the manufacturer’s instructions prior to applying coatings.

DURABILITY

Durascape™ physical properties make it a very durable product.

/ Durascape™ panels are immune to permanent water damage in both short and long-term exposure./ Durascape™ panels will not rot or burn and are unaffected by termites, air, steam, salt and sunlight./ Durascape™ panels are not adversely affected over a temperature range of 0°C to 95°C.

Vapour permeable sarking must be installed in accordance with the AS/NZS 4200.2 – ‘Pliable building membranes and underlays – Installation’ and the sarking manufacturer’s guidelines. The sarking should have the following properties:

/ Vapour barrier – low or medium/ Water barrier – high

Vapour permeable sarking is used to prevent moisture ingress by acting as a drainage plane whilst enabling water vapour build up from inside the frame to escape.

LENGTH mmTHICKNESSmm

9

WEIGHTkg/m2

13.5

WIDTHmm

9001200

2450•

•

3000•

•

THERMAL CONDUCTIVITY

WEATHER RESISTANCE / FREEZE THAW

SHEET TOLERANCES

Durascape™ panels have relatively low thermal conductivity: R-value. At Equilibrium Moisture content the approximate R-Value of Durascape™ is;- 0.55 W/m°C.

/ Width +0/-2mm/ Length +0/-2mm/ Thickness +10%/-0%/ Diagonals difference (max) 2mm/ Edge straightness deviation (max) 1mm

SIZES AND WEIGHT

Durascape™ conforms to the Building Code of Australia (BCA) requirements for external wall applications. Durascape™ facade system has been tested to AS/NZS 4284 Testing of Building Facades.

Durascape™ subject to freeze/thaw conditions must be painted. Durascape™ should not be used in situations where it will be in direct contact with snow or ice for prolonged periods.

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COASTAL AREAS

The durability of galvanised nails and screws used for exterior cladding in coastal or similar corrosive environments can be as low as 10 years.

For this reason BGC recommend the use of stainless steel fasteners within 1km of the coast or other large expanses of salt water.

HEALTH AND SAFETY

AVOID DUST INHALATION

Durascape™ is manufactured from cellulose fibre, finely ground sand, Portland cement and additives. As manufactured, the product will not release airborne dust, but during drilling, cutting and sanding operations cellulose fibres, silica and alcium silicate dust may be released.

Breathing in fine silica dust is hazardous and prolonged exposure (usually over several years) may cause bronchitis, silicosis or cancer.

When cutting sheets, work in a well-ventilated area and use the methods recommended in this literature to minimise dust generation. If using power tools wear an approved (P1 or P2) dust mask and safety glasses.

These precautions are not necessary when stacking, unloading or handling fibre cement products.

For further information or a Material Safety Data Sheet contact the nearest BGC Sales Office or go towww.bgcinnovadesign.com.au

CUTTING AND DRILLING

The most suitable cutting methods are:

/ DURABLADE 180mm Diameter. This unique cutting blade is ideal for cutting Fibre Cement. Can be fitted to a 185mm circular saw, ie Makita or similar. Please ensure safe working practices when using.

/ NOTCHING Notches can be made by cutting the two sides of the notch. Score along the back edge then snap upwards to remove the notch.

/ DRILLING Use normal high-speed masonry drill bits. Do not use the drill’s hammer function. For small round holes, the use of a hole-saw is recommended. For small rectangular or circular penetrations, drill a series of small holes around the perimeter of the cut out. Tap out the waste piece from the sheet face while supporting the underside of the opening to avoid damage. Clean rough edges with a rasp.

Large rectangular openings are formed by deeply scoring the perimeter of the opening. Next, form a hole in the centre of the opening (refer method above) then saw cut from the hole to the corners of the opening. Snap out the four triangular segments. Clean rough edges with a rasp. (see method above) then saw cut from the hole to the corners of the opening. Snap out the four triangular segments. Clean rough edges with a rasp

HANDLING AND STORAGE

Durascape™ must be stacked flat, up off the ground and supported on equally spaced (max 400mm) level gluts.

Care should be taken to avoid damage to the ends, edges and surfaces.

Sheets must be kept dry. When stored outdoors it must be protected from the weather. Sheets must be dry prior to fixing, jointing or finishing.

EXTRA CARE MUST BE TAKEN AT THE SHEET EDGES TO PREVENT CRACKING OF THE SHIPLAP JOIN.

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2.8 x 40mm Gun Nail (minimum Class 3 corrosion resistant)

/ Screws should be countersunk 1.5mm and filled with BGC Exterior Finishing Compound or epoxy filler such as Megapoxy P1, Hilti CA125 or Hilti CA273 and sanded flush to provide a flat surface for finish coating.

/ Nails must be driven flush to the panel surface.

DURASCAPETM TO TIMBER FRAME DURASCAPETM TO STEEL FRAME

DURASCAPETM ACCESSORIES AVAILABLE FROM BGC

FASTENERS

EPDM FOAM GASKET (Used to prevent moisture ingress at sheet joins).

INTERNAL CORNER

EXTERNAL CORNER

HORIZONTAL FLASHING

25m

3000mm

3000mm

3000mm

2.8 x 30mm Fibre Cement Nail (minimum Class 3 corrosion resistant)

To Steel – 0.75BMT No 8 x 30mm Countersunk Self Drilling (minimum Class 3 corrosion resistant)

To Steel - 0.8-1.6BMT8 x 32mm Wingtek Self Embedding Head Screw (minimum Class 3 corrosion resistant)

BGC PRODUCT CODE 845

BGC PRODUCT CODE INTCNR12

BGC PRODUCT CODE EXTCNR12

BGC PRODUCT CODE HORIZ9

DURASCAPETM

MAY - 2015

MAXIMUM STUD & FASTENER SPACING

Durascape™ panels can be installed vertically to both timber and lightweight steel frames.

Ensure that the frame is square and work from a central datum line. The frame must be straight and true to provide a flush face to receive the panels.

BGC recommend a maximum tolerance of 3mm-4mm in any 3000mm length of frame.

Durascape™ will not straighten excessively warped or distorted frames and any warping may still be visible after Durascape™ is applied. Warped framing will require remedial action.

CONSTRUCTION DETAILS

FRAMING TIMBER FRAMES

LIGHTWEIGHT STEEL FRAMES

Use of a timber frame must be in accordance with AS1684 – Residential timber-framed construction and the framing manufacturers’ specifications.

Use only seasoned timber. Do not use unseasoned timber as it is prone to shrinkage and can cause sheets and frames to move up.

“Timber used for house construction must have the level of durability appropriate for the relevant climate and expected service life conditions including exposure to insect attacks or to moisture which could cause decay” – Reference AS 1684.2

The framing width at sheet joints must be a minimum of 45mm. The intermediate support studs should be a minimum width of 35mm.

Use of steel frame must be in accordance with AS3623 – Domestic metal framing and the framing manufacturers’ specifications.

Framing members must have a Base Metal Thickness (BMT) between 0.50 to 1.6mm. The steel framing must have the appropriate level of durability required to prevent corrosion.

The framing width at sheet joints must be a minimum of 50mm. The intermediate support studs should be a minimum of 64 x 35mm.

WITHIN 1200MM OF BUILDING EDGES (MM)

GENERAL AREAS OF WALLS (MM)

N1, N2, N3, N4N5N6

C1, C2C3C4

600450450600450450

200200150200200150

600300300600300300

200150125200150125

Fastener Spacing

Stud Spacing

(mm)

Wind Classification

AS4005

Stud Spacing

Fastener Spacing

FIGURE 1 FRAME STRAIGHTNESS

DURASCAPETM

MAY - 2015

Durascape™ panels should be installed vertically with all sheet edges fully supported. The centre joints must coincide with the

At every vertical joint, fix a continuous strip of EPDM Foam Gasket to the vapour permeable sarking along the stud. This assists to prevent the ingress of moisture at the sheet joins.

centre lines of the framing member and all sheets should be installed in one direction.

Position the underlap sheet on every stud 3mm past the centre of the stud to ensure the fasteners fixed at the edge of the sheet have adequate distance into the stud.

INSTALLATION DETAILS

FIGURE 2 FASTENER POSITIONING

600mm max

50mm from corner

200mm max 200mm max

12mm from top edge

EPDM Foam Gasket

Vapour Permeable Sarking*


EPDM Foam Gasket

FIGURE 3 APPLY EPDM FOAM GASKET

FIGURE 4 SHEET EDGE POSITION

Overlap sheet by 3mm beyond centre of the stud

*Components not supplied by BGC

DURASCAPETM

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As detailed on p6, there are several different fasteners that can be used to fix Durascape™ panels.


Vapour Permeable Sarking*Vapour Permeable Sarking*

Durascape™ Durascape™

EPDM Foam Gasket EPDM Foam Gasket

Fibre Cement Nails

Continuous bead of sealant Continuous bead of sealant

FIGURE 5FIBRE CEMENT NAIL FIXING – TIMBER FRAME

FIGURE 6FLUSH SCREW – LIGHTWEIGHT STEEL FRAME

18mm 22mm

Durascape™

EPDM Foam Gasket

FIGURE 7COUNTERSUNK SCREW – LIGHTWEIGHT STEEL FRAME

Screws-countersunk 1.5mm Finish with Epoxy

Continuous bead of sealant



DURASCAPETM

MAY - 2015


To fix the first sheet, set in place ensuring the required edge distances are maintained.

Apply of continuous 4mm bead of sealant to the edge of the shiplap join.

Vapour Permeable Sarking* Vapour Permeable Sarking*

Durascape™ Durascape™

EPDM Foam Gasket EPDM Foam Gasket

4mm continuous bead of sealant

FIGURE 8FIX FIRST SHEET

FIGURE 9APPLY SEALANT

FIGURE 10FIX NEXT SHEET


Durascape™

EPDM Foam Gasket

Once both sheets are fixed, check the joint for gaps and fill with additional sealant if required.


DURASCAPETM

MAY - 2015


FIGURE 11SLAB EDGE/EAVE JUNCTION

Damp Course*


DurascapeTM

The architectural intent and details of buildings vary from one designer to the next, and the variety of facade details would be impossible to catalogue.

The detail diagrams following are intended to assist the designer in achieving a high quality weather resistant Durascape™ installation.

The designer should not digress from the specification set out in this manual.


DURASCAPETM

MAY - 2015


FIGURE 12EXTERNAL CORNER – SEALANT OPTION

DurascapeTM

Bond Breaker Tape*


Corner flashing*


FIGURE 13EXTERNAL CORNER – STEEL

DurascapeTM


Corner flashing*


BGC External corner angle


DURASCAPETM

MAY - 2015


FIGURE 14INTERNAL CORNER – SEALANT OPTION

DurascapeTM

Bond Breaker Tape*


Flashing*


FIGURE 15INTERNAL CORNER – STEEL

DurascapeTM


BGC Internal corner angle



Corner flashing*

DURASCAPETM

MAY - 2015



FIGURE 17WINDOW SILL


DurascapeTM

Flashing*

FIGURE 16WINDOW HEAD

Flashing*


Optional trim*


6mm


DURASCAPETM

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FIGURE 19VERTICAL BUTT JOINT



EPDM Foam Gasket

DurascapeTM

1mm

FIGURE 18WINDOW JAMB


DurascapeTM

Sealant

Trim*


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FIGURE 21UPPER FLOOR JUNCTION

Flooring*


BGC Horizontal Flashing

DurascapeTM

DurascapeTM

FIGURE 20LOWER FLOOR JUNCTION


Flooring*

DurascapeTM

Damp Course*

20-5

0mm

ov

erla

p


DURASCAPETM

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FIGURE 23HORIZONTAL JUNCTION 1


Suitable flashing*

Damp course*

Masonry wall*

DurascapeTM

10m

m


DurascapeTM

DurascapeTM

FIGURE 22UPPER FLOOR JUNCTION – OPTION 2


Architectural profile or similar*


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FIGURE 24HORIZONTAL JUNCTION 2


Suitable flashing*

Masonry wall*

DurascapeTM

20m

m

WARRANTY

We warrant that our products are free from defects caused by faulty manufacture or materials for a period of 15 years from the date of purchase. If you acquire any defective products, we will repair or replace them, supply equivalent replacement products or refund the purchase price within 30 days of receiving a valid claim subject to product inspection and confirmation of the existence of a defect by BGC. We will bear the cost of any such repair, replacement or refund.

This warranty is given by: BGC Fibre Cement Pty Ltd121 Bannister Rd Canningvale WA 6155Phone 08 9334 4900 Fax 08 9334 4749 To claim under this warranty, you must provide proof of purchase as a consumer and make a written claim (including any costs of claiming) to us at the address specified above within 30 days after the defect was reasonably apparent, or if the defect was reasonably apparent prior to installation, the claim must be made prior to installation. You may not claim under this warranty for loss or damage caused by:• faulty or incorrect installation by non-BGC installers (BGC’s installation procedures are at www.innovadesign.com.au);• failure to comply with the Building Code of Australia or any applicable legislation, regulations approvals and standards;• products not made or supplied by BGC;• abnormal use of the product; or• normal wear and tear.The benefits available under this warranty are in addition to other rights and remedies of the consumer under the law. Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.

Designers, specifiers and builders have a duty of care to identify moisture-associated risks with any individual building design.

Wall construction design should consider both the interior and exterior environments of the building to effectively manage moisture. Special consideration should be given to buildings that are in extreme climates or at higher risk of wind driven rain.

In addition, all wall openings, penetrations, junctions, connections, window heads, sills and jambs must incorporate appropriate flashing for waterproofing. All other components, materials and installation methods used to manage moisture in walls should comply with the relevant standards of the Building Code of Australia (BCA).

MOISTURE MANAGEMENT


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FIGURE 25THERMAL BREAKS

DurascapeTM

Vapour Permeable Sarking*EPDM Foam Gasket

THERMAL BREAKS

Thermal breaks are required for steel framed buildings, in walls enclosing habitable and or usable spaces. Careful consideration of thermal heat transfer and the position of thermal breaks need to be addressed by the architects, engineers and building designers.

Balustrades, parapets, and other non-enclosing wall elements may not require thermal bridging, except where the possibility of high thermal heat transfer exists through the steel CFS sections to the main structural steel element of the building.

As part of the Durascape™ range EPDM Foam Gasket is required to prevent moisture ingress at sheet joins. EPDM Foam Gasket can also be used as a Thermal Break Tape and provides an R value of R 0.2 in accordance with the Building Code of Australia.

The EPDM Foam Gasket should be placed on all frame contact faces and at noggins and bottom plates. Refer Figure 25

Thermal breaks are first installed to all vertical frame members (Studs) then applied horizontally to top and bottom tracks as well as any horizontal noggins.

NOTE: Thermal breaks (BGC EPDM Foam Gasket) is a self adhesive foam gasket/tape. It is installed over the building wrap (sarking), refer figure 25.

Leave a small gap between the vertical gasket to allow any moisture to escape.


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FIGURE 26BOUNDARY WALL SYSTEM

DurascapeTM

16mm BGC Wet Area Fireboard

Vapour Permeable Sarking*EPDM Foam Gasket

10mm BGC Plasterboard

BUSHFIRE AND BOUNDARY WALL AREAS

Durascape™ is eminently suited for both bushfire and boundary wall applications in residential and multi residential buildings.

Durascape™ can be used as a stand alone product to achieve up to BAL 40 when fixed direct to frame as per the fixing instructions in this manual.

Durascape™ when used in conjunction with BGC 16mm Wet Area Fireboard will comply with the requirements of AS3959:2009 and AS1530.4 to achieve BAL FZ>10 as well as 60 minute and 90 minute boundary wall systems.

Durascape™ in conjunction with BGC 16mm Wet Area Fire-board can achieve both 60/60/60 and 90/90/90 FRL fire ratings from the outside as required by the BCA.

Where an exterior wall is required to achieve 60/60/60 FRL (Fire Resistance Level) from the outside, 1 layer of 16mm BGC Wet Area Fireboard installed with Durascape™ over the Wet Area Fireboard will meet minimum BCA requirements.Similarly 2 layers of 16mm BGC Wet Area Fireboard used in conjunction with Durascape™ will achieve 90/90/90 from the outside.

NOTE: All external walls must have sarking beneath the Durascape™. No adhesives are to be used when installing Wet Area Fireboard and the Durascape™. Nails or screws must be used. For more information please contact your nearest BGC Fibre Cement office.

BOUNDARY/EXTERIOR WALLS

AS3959:2009 sets out a series of Bushfire threat levels to buildings described as BAL (Bushfire Attack Levels) as follows: BAL-Low, BAL-12.5, BAL-19, BAL-29, BAL-40 or BAL-FZ (Flamezone).

Durascape™ may be used to achieve a BAL-40 or BAL-FZ>10 when used in conjunction with 16mm Wet Area Fireboard.

BUSHFIRE AS3959:2009 APPLICATIONS

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NOTES

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NOTES

CONTACT

AUSTRALIAN OWNED & MANUFACTURED WWW.BGCINNOVADESIGN.COM.AU

DESIGN WWW.THESHAPEGROUP.COM.AU

TO CONTACT YOUR NEAREST BGC STOCKIST, PLEASE CALL:

ADELAIDETELEPHONE 08 8250 4962BRISBANETELEPHONE 07 3271 1711MELBOURNETELEPHONE 03 9392 9444PERTHTELEPHONE 08 9334 4900SYDNEYTELEPHONE02 9771 9660

NEW ZEALANDTELEPHONE0011 64 9273 1457

TECHNICAL HELP LINE1300 652 242

BGC FIBRE CEMENT IS A PROUD AUSTRALIAN OWNED MANUFACTURER OF FIBRE CEMENT PRODUCTS.

BGC FIBRE CEMENT PROVIDES BUILDERS, DEVELOPERS AND ARCHITECTS WITH A RANGE OF DESIGN ALTERNATIVES AND INNOVATIVE PRODUCTS, SUCH AS:

EXTERIOR PRODUCTS AND APPLICATIONSINNOVA RANGE OF PRODUCTS

DURACOMTM / A compressed fibre cement facade system.DURAFLOORTM / Is the ultimate flooring product that can be used in both interior and exterior applications. DURAGRIDTM RESIDENTIAL & DURAGRIDTM LIGHT COMMERCIAL / A light weight facade giving a modern and durable finish.DURAGROOVETM / A vertically grooved exterior facade panel.DURASCAPETM / A lightweight exterior facade base sheet with a subtle vertical shadow line. NULINETM PLUS / A weatherboard style cladding system.STONESHEETTM / Purpose designed substrate for stone tile facade. STRATUMTM / Is a trio of plank products, each of which can be used as stand alone products or used together to create a striking exterior cladding solution.STRATUMTM ERA / A traditional, yet contemporary as it is flat weatherboard.

EXTERIOR PRODUCTS AND APPLICATIONSBGC FIBRE CEMENT RANGE OF PRODUCTS

DURASHEETTM / Ideal for the cladding of gables and lining of eaves. Can also be used on commercial soffits and cladding on non impact areas.DURAPLANKTM / Available in Smooth, Woodgrain and Rusticated finishes, DuraplankTM is ideal for exterior cladding of upper storey conversions or ground level extensions.DURATEXTM / A base sheet used for textured coatings on exterior wall applications.DURALINERTM PLUS / An exterior lining board, this is the perfect substrate for tiles and is ideal for wet areas. DURALATTICETM / Square or diamond patterned lattice, suitable for screens, pergolas and fences.COMPRESSED / Used for domestic, commercial sheet for wet areas, flooring, partitions, exterior decking, fascia and facade cladding.DURALUXTM PLUS / Suitable for exterior applications where it will be sheltered from direct weather.

INTERIOR PRODUCTS AND APPLICATIONSBGC FIBRE CEMENT RANGE OF PRODUCTS

DURALUXTM PLUS / An interior lining board suitable for ceilings and soffits.DURALINERTM PLUS / An interior lining board, this is the perfect substrate for tiles and is ideal for wet areas.CERAMIC TILE UNDERLAY / A substrate for ceramic and slate floor tiles.VINYL CORK FLOOR COVERINGS / A substrate for vinyl floors.

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